Selective thickening of pfet dielectric

ABSTRACT

A complementary metal-oxide semiconductor (CMOS) device and a method of fabricating a CMOS device are described. The method includes forming an interfacial layer in a trench on a substrate in both a p-channel field effect transistor (pFET) area of the CMOS device and an n-channel FET (nFET) area of the CMOS device, depositing a high-k dielectric on the interfacial layer in both the pFET area and the nFET area, selectively forming a first metal layer on the high-k dielectric in only the pFET area, and depositing a second metal layer on the first metal layer in the pFET area and on the high-k dielectric in the nFET area. The method also includes performing an anneal that increases a thickness of the interfacial layer in only the pFET area.

BACKGROUND

The present invention relates to complementary metal-oxide semiconductor(CMOS) technology, and more specifically, to selective thickening ofp-type or p-channel field effect transistor (pFET) dielectric.

A CMOS device typically includes complementary and symmetrical pairs ofp-type and n-type metal oxide semiconductor field effect transistors(MOSFETs) or a pFET and n-type or n-channel FET (nFET) pair.Negative-bias temperature instability (NBTI) is a reliability issue inthe pFET region or area of the CMOS device in particular and manifestsas an increase in threshold voltage and corresponding decrease in draincurrent. NBTI limits the scaling of inversion layer thickness (Tinv).

SUMMARY

According to one embodiment of the present invention, a method offabricating a complementary metal-oxide semiconductor (CMOS) deviceincludes forming an interfacial layer in a trench on a substrate in botha p-channel field effect transistor (pFET) area of the CMOS device andan n-channel FET (nFET) area of the CMOS device; depositing a high-kdielectric on the interfacial layer in both the pFET area and the nFETarea; selectively forming a first metal layer on the high-k dielectricin only the pFET area; depositing a second metal layer on the firstmetal layer in the pFET area and on the high-k dielectric in the nFETarea; and performing an anneal that increases a thickness of theinterfacial layer in only the pFET area.

According to another embodiment, a complementary metal-oxidesemiconductor (CMOS) device includes an n-type field effect transistor(nFET) region, the nFET region including an interfacial layer of a firstthickness formed on an nFET substrate; and a p-type field effecttransistor (pFET) region, the pFET region including the interfaciallayer of a second thickness formed on a pFET substrate, the firstthickness being less than the second thickness.

Additional features and advantages are realized through the techniquesof the present invention. Other embodiments and aspects of the inventionare described in detail herein and are considered a part of the claimedinvention. For a better understanding of the invention with theadvantages and the features, refer to the description and to thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The forgoing and other features, and advantages ofthe invention are apparent from the following detailed description takenin conjunction with the accompanying drawings in which:

FIGS. 1-13 are cross sectional views illustrating stages in theformation of a CMOS device according to embodiments of the invention, inwhich:

FIG. 1 is a cross sectional view of an intermediate structure in theCMOS fabrication process according to an embodiment;

FIG. 2 shows the result of deposition of a metal layer on the structureshown in FIG. 1;

FIG. 3 results from removal of the metal layer from the nFET area;

FIG. 4 is a cross sectional view of an intermediate structure resultingfrom deposition of another metal layer on the structure shown in FIG. 3;

FIG. 5 results from deposition of an amorphous silicon layer;

FIG. 6 shows the thicker interfacial layer in the pFET area resultingfrom a rapid thermal anneal (RTA) process;

FIG. 7 results from removal of the amorphous silicon layer;

FIG. 8 shows the result of an optional removal of the metal layers;

FIG. 9 shows the structure resulting from deposition of a pFETworkfunction setting metal layer in both the nFET and pFET areas;

FIG. 10 results from removal of the pFET workfunction setting metallayer from the nFET area;

FIG. 11 is the structure resulting from deposition of an nFETworkfunction setting metal layer in both the nFET and pFET areas;

FIG. 12 shows the intermediate structure of FIG. 11 with a lowresistivity metal layer deposited in both the nFET and pFET areas; and

FIG. 13 shows the result of chemical mechanical planarization on thestructure of FIG. 12;

FIGS. 14-16 illustrate an alternate embodiment of the processes shown inFIGS. 9-11, in which:

FIG. 14 shows the structure resulting from deposition of an nFETworkfunction setting metal layer in both the nFET and pFET areas;

FIG. 15 results from removal of the nFET workfunction setting metallayer from the pFET area; and

FIG. 16 is the structure resulting from deposition of a pFETworkfunction setting metal layer in both the nFET and pFET areas.

DETAILED DESCRIPTION

As noted above, in a CMOS device, NBTI limits the scaling of Tiny in thepFET. Embodiments detailed herein relate to fabricating the pFET with athicker interfacial layer or IL. The thicker interfacial layer improvesNBTI in the pFET. Further, because there is limited equivalent oxidethickness (EOT) increase in the nFET, any performance penalty for thenFET resulting from the improved NBTI for the pFET is also limited.

FIGS. 1-13 are cross sectional views illustrating stages in theformation of a CMOS device 100 according to embodiments of theinvention. FIG. 1 is a cross sectional view of an intermediate structureof the CMOS 100 according to an embodiment. FIG. 1 specificallyillustrates a point in high-k metal gate (HKMG) processing followingdummy gate removal. The nFET 10 and the pFET 20 may be electricallyisolated from each other as shown in the figures. In alternateembodiments, the nFET 10 and pFET 20 may be coupled and may share asubstrate 110. An interlayer dielectric 120 is formed on the substrate110 of each of the nFET 10 and the pFET 20. The interlayer dielectric120 may be silicon dioxide (SiO₂), for example. In the intermediatestage shown in FIG. 1, a trench 126 is formed in the interlayerdielectric 120 with spacers 125 on either side of the trench. Thespacers 125 may be formed from silicon nitride (SiN), for example. Thetrench 126 is formed as a result of the dummy gate removal. Aninterfacial layer 130 is formed on the substrate 110 in the trench 126.The interfacial layer 130 may be comprised of SiO₂ or silicon oxynitride(SiON) and may typically range in thickness from 0.5 to 1.0 nanometers(nm), for example. Alternate embodiments contemplate other thicknessesfor the interfacial layer 130. A high-k dielectric 140 is conformallydeposited on the interfacial layer 130, spacers 125, and interlayerdielectric 120. Many high-k dielectric materials are known and aretypically deposited using atomic layer deposition (ALD). Exemplaryhigh-k dielectric 140 materials include hafnium oxide (HfO₂), zirconiumoxide (ZrO₂), lanthanum oxide (La₂O₃) and aluminum oxide (Al₂O₃).

FIG. 2 is a cross-sectional view of the structure resulting from theconformal deposition of a metal layer 135 on the high-k dielectric 140on both the nFET 10 and pFET 20 sides. The metal layer 135 may betitanium nitride (TiN), titanium carbide (TiC), tantalum nitride (TaN),or tantalum carbide (TaC), for example. FIG. 3 shows the structureresulting from removal of the metal layer 135 from only the nFET 10region. This removal may be accomplished by using a resist mask and awet etch process, for example. As shown in FIG. 4, a metal layer 145 isdeposited conformally on the metal layer 135 in the pFET 20 region andon the high-k dielectric 140 in the nFET 10 region. The metal layer 145may be TiN, TiC, TaN, or TaC, for example. FIG. 5 is a cross-sectionalview of an intermediate structure with a dummy amorphous silicon layer150 deposited in the trench 126 and on the metal layer 145 in the nFET10 and pFET 20 areas. A rapid thermal anneal (RTA) process may beperformed on the structure shown in FIG. 5. The anneal temperature maybe 800 to 1100 degrees Celsius. The duration of the anneal process mayvary from a spike (no hold time at the peak temperature) to a hold timeat the peak temperature of 5 seconds. The anneal conditions may includeambient nitrogen. Alternatively, a millisecond anneal (e.g., a laseranneal or flash lamp anneal) may be may be performed. The anneal processresults in the structure shown in FIG. 6, in which the interfacial layer130 in the pFET 20 area is thicker than the interfacial layer 130 in thenFET 10 area. The thicker interfacial layer 130 in the pFET 20 areaimproves NBTI in the pFET 20 area. The thicker interfacial layer 130results from the fact that dissolved oxygen in a metal layer generallycauses interfacial layer growth during anneal. Because of the additionalmetal layer 135 in the pFET 20 area as compared to the nFET 10 area, alarger amount of dissolved oxygen results in the pFET 20 area. Thisadditional dissolved oxygen, in turn, results in the thicker interfaciallayer 130 in the pFET 20 area. The additional thickness may be in therange of 0.05 to 0.4 nm, for example. As noted above with regard to theinitial interfacial layer 130 thickness, values outside the exemplaryranges are contemplated, as well. The additional thickness in the pFET20 region, resulting from the additional metal layer 135, is the commonfeature of the embodiments.

FIG. 7 is the intermediate structure resulting from removal of the dummyamorphous silicon layer 150 from both the nFET 10 and pFET 20 regions.Optionally, the metal layer 135 from the pFET 20 area and the metallayer 145 from both the nFET 10 and pFET 20 areas may be removed,stopping on the high-k dielectric layer 140, resulting in the structureshown in FIG. 8. A pFET workfunction setting metal layer 155 isconformally deposited in both the nFET 10 and pFET 20 regions, resultingin the structure shown in FIG. 9. The pFET workfunction setting metallayer 155 may be TiN. The pFET workfunction setting metal layer 155 isremoved from only the nFET 10 area to provide the structure shown inFIG. 10. As shown in FIG. 11, an nFET workfunction setting metal layer160 is then conformally deposited on the pFET workfunction setting metallayer 155 in the pFET 20 area and on the high-k dielectric 140 in thenFET 10 area. The nFET workfunction setting metal layer 160 may be analuminum alloy, for example. In FIG. 12, a low resistivity metal layer165 is deposited in the trench 126 and on the nFET workfunction settingmetal layer 160 in both the nFET 10 and pFET 20 areas. The lowresistivity metal layer 165 may be aluminum (Al) or tungsten (W), forexample. The structure shown in FIG. 13 results from a chemicalmechanical planarization (CMP) process on the structure shown in FIG. 12to achieve device isolation. From this stage, conventional processes maybe performed to complete the fabrication of the CMOS device 100. TheCMOS device 100 will have an pFET 20 with a thicker interfacial layer130 than the nFET 10.

FIGS. 14-16 illustrate an alternate embodiment to the one shown in FIGS.9-11. FIGS. 14-16 illustrate processes analogous to processes shown inFIGS. 9-11, which all occur after the thickening of the interfaciallayer 130 in the pFET 20 region. FIG. 14 results from the deposition ofthe nFET workfunction setting metal layer 160 on the high-k dielectric140 in both the nFET 10 and pFET 20 areas. The nFET workfunction settingmetal layer 160 is then removed from the pFET 20 region to result in thestructure of FIG. 15. The pFET workfunction setting metal layer 155 isthen deposited on the high-k dielectric 140 in the pFET 20 region and onthe nFET workfunction setting metal layer 160 in the nFET 10 area, asshown in FIG. 16. At this stage, deposition of the low resistivity metallayer 165 (see FIG. 12) and other known processing steps may becompleted to fabricate the CMOS device 100.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of onemore other features, integers, steps, operations, element components,and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theembodiment was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious embodiments with various modifications as are suited to theparticular use contemplated

The flow diagrams depicted herein are just one example. There may bemany variations to this diagram or the steps (or operations) describedtherein without departing from the spirit of the invention. Forinstance, the steps may be performed in a differing order or steps maybe added, deleted or modified. All of these variations are considered apart of the claimed invention.

While the preferred embodiment to the invention had been described, itwill be understood that those skilled in the art, both now and in thefuture, may make various improvements and enhancements which fall withinthe scope of the claims which follow. These claims should be construedto maintain the proper protection for the invention first described.

The descriptions of the various embodiments of the present inventionhave been presented for purposes of illustration, but are not intendedto be exhaustive or limited to the embodiments disclosed. Manymodifications and variations will be apparent to those of ordinary skillin the art without departing from the scope and spirit of the describedembodiments. The terminology used herein was chosen to best explain theprinciples of the embodiments, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the embodimentsdisclosed herein.

1. A method of fabricating a complementary metal-oxide semiconductor(CMOS) device, the method comprising: forming an interfacial layer on asubstrate in both a p-channel field effect transistor (pFET) area of theCMOS device and an n-channel FET (nFET) area of the CMOS device;depositing a high-k dielectric on the interfacial layer in both the pFETarea and the nFET area; selectively forming a first metal layer on thehigh-k dielectric in only the pFET area; depositing a second metal layeron the first metal layer in the pFET area and on the high-k dielectricin the nFET area; performing an anneal that increases a thickness of theinterfacial layer in only the pFET area: and removing a dummy amorphoussilicon layer formed on the second metal layer in both the pFET area andthe nFET area following the increasing the thickness of the interfaciallayer in only the pFET area.
 2. The method according to claim 1, furthercomprising forming a trench on the substrate in both the pFET area andthe nFET area within an interlayer dielectric using spacers.
 3. Themethod according to claim 2, wherein the depositing the high-kdielectric is conformally over the interlayer dielectric, the spacers,and the interfacial layer.
 4. (canceled)
 5. The method according toclaim 1, further comprising removing the second metal layer from thepFET area and the nFET area.
 6. The method according to claim 5, furthercomprising removing the first metal layer from the pFET area.
 7. Themethod according to claim 6, further comprising depositing a pFETworkfunction setting metal layer on the high-k dielectric in both thepFET area and the nFET area.
 8. The method according to claim 7, furthercomprising removing the pFET workfunction setting metal layer in thenFET area.
 9. The method according to claim 8, further comprisingdepositing an nFET workfunction setting metal layer on the pFETworkfunction setting metal layer in the pFET area and on the high-kdielectric in the nFET area.
 10. The method according to claim 6,further comprising depositing a nFET workfunction setting metal layer onthe high-k dielectric in both the pFET area and the nFET area.
 11. Themethod according to claim 10, further comprising removing the nFETworkfunction setting metal layer in the pFET area.
 12. The methodaccording to claim 11, further comprising depositing an pFETworkfunction setting metal layer on the nFET workfunction setting metallayer in the nFET area and on the high-k dielectric in the pFET area.13. The method according to claim 1, wherein the performing the annealincludes performing a rapid thermal anneal (RTA) process.
 14. The methodaccording to claim 1, wherein the performing the anneal includesperforming a laser anneal or a flash lamp anneal. 15-20. (canceled)